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The first problem and probably one of the most common reaming problems is Poor Finish. Possible causes include unequal chamfers, incorrect margins, excessive spindle runout, chatter, and insufficient cutting action. Below is a table with possible solutions for each of the possible causes of poor finish:
| Possible Causes | Possible Solutions |
| Unequal Chamfers | Regrind the reamer with equal chamfer heights. |
| Incorrect Margins | Regrind the reamer with narrower margins for reaming higher tensile materials. |
| Excessive Spindle Runout | Use bushings that are .0002″/.0003″ over the reamer’s diameter. |
| Chatter | Increase feed and reduce the speed rate. |
| Use power feed unless the material being reamed is hard. | |
| Use a spiral fluted reamer. | |
| Grind a secondary lead angle directly behind the 45° chamfer. | |
| Insufficient Cutting Action | Use a reamer with positive radial rake to reduce the cutting pressure. This may produce slightly larger diameter holes. |
Another common reaming problem is the shape of the reamed hole including Oversized Holes, Tapered Holes, and Bell Mouth Holes. Possible causes include misalignment and using the incorrect feed and/or speed. Below is a table with possible solutions for each of the possible causes of Oversized Holes, Tapered Holes, and Bell Mouth Holes:
| Possible Causes | Possible Solutions |
| Misalignment | Check fixturing & setup for possible causes; use floating tool holder if necessary. Consider using precision bushings or piloted reamers. |
| Incorrect feed and/or speed rate | Verify correct feeds and speeds. |
| See previous post Reaming Speeds and Feeds. |
Another common reaming problem is Excessive Tool Wear. Possible causes include improper amount of stock removal, excessive reaming pressure, and misalignment. Below is a table with possible solutions for each of the possible causes of Excessive Tool Wear:
| Possible Causes | Possible Solutions |
| Improper Amount of Stock Removal | Change pre-ream hole size to leave 2 to 3% of tool diameter. See previous post Pre-Ream Hole Size. |
| Excessive Reaming Pressure | Decrease feed rate. See previous post Reaming Speeds and Feeds. |
| Change pre-ream hole size to leave 2 to 3% of tool diameter. See previous post Pre-Ream Hole Size. | |
| Misalignment | Check fixturing & setup for possible causes; use floating tool holder if necessary. Consider using precision bushings or piloted reamers. |
Another common reaming problem is Crooked Holes. The most likely culprit here is the drill walking or incorrect sharpening of the reamer. Below is a table with solutions for the possible causes of Crooked Holes:
| Possible Causes | Possible Solutions |
| Drill Walking | Correct the drilling operation. A reamer will follow the drilled hole. |
| Incorrect sharpening of the reamer | Increase the 90° included chamfer angle to 120° – 180° |
Another common reaming problem is Tool Breakage. Below is a table with solutions for the possible causes of Tool Breakage:
| Possible Causes | Possible Solutions |
| Excessive Reaming Pressure | Decrease feed rate. See previous post Reaming Speeds and Feeds. |
| Change pre-ream hole size to leave 2 to 3% of tool diameter. See previous post Pre-Ream Hole Size. | |
| Misalignment | Check fixturing & setup for possible causes; use floating tool holder if necessary. Consider using precision bushings or piloted reamers. |
I’ve addressed the most common problems encountered while reaming but this post by no means addresses them all. If you are having issues reaming please leave us a comment here or drop us a line on Super Tool’s Contact Us page. We are happy to help.
Bryan Enander
Super Tool, Inc.
941-751-9677